Fireplace grate

ABSTRACT

According to an embodiment, a fireplace grate is disclosed. The fireplace grate includes a plurality of cross bars, a plurality of support bars, and a plurality of fasteners. The plurality of support bars and the plurality of cross bars can be nested together in a disassembled configuration. Each fastener is configured to extend through a hole in one of the cross bars and engage a corresponding threaded hole in one of the support bars so that each cross bar can be fastened to the plurality of support bars in an assembled configuration with each cross bar spanning the plurality of support bars. A width of the fireplace grate in the disassembled configuration is less than 50% of a width of the fireplace grate in the assembled configuration.

SUMMARY

Embodiments of the present disclosure provide for a fireplace grate that is assembled by the end user, thereby providing a full-size fireplace grate that can be shipped and displayed on store shelves with a relatively compact size.

BRIEF DESCRIPTION OF THE DRAWINGS

So that the manner in which the above recited features of the present disclosure can be understood in detail, a more particular description of the disclosure, briefly summarized above, may be had by reference to embodiments, some of which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only exemplary embodiments and are therefore not to be considered limiting of its scope, may admit to other equally effective embodiments.

FIG. 1 is a perspective view of a fireplace grate in an assembled configuration according to an embodiment;

FIG. 2 is a perspective view of the fireplace grate in a packaged and disassembled configuration;

FIG. 3 is a partial perspective view of the fireplace grate showing an assembly procedure;

FIG. 4 is a partial cross section view of the fireplace grate showing details of a connection point;

FIG. 5 is a perspective view of example alternative embodiments of the fireplace grate;

FIG. 6 is a table identifying example dimensions and weight analysis of the alternative embodiments of FIG. 5 ;

FIG. 7 is a perspective view of one of the alternative embodiments of FIG. 5 in an assembled configuration; and

FIG. 8 is a perspective view of the fireplace grate of FIG. 7 in a packaged and disassembled configuration.

To facilitate understanding, identical reference numerals have been used, where possible, to designate identical elements that are common to the figures. It is contemplated that elements and features of one embodiment may be beneficially incorporated in other embodiments without further recitation.

DETAILED DESCRIPTION

Embodiments of the present invention generally related to a fireplace grate that may be suitable for holding logs and the like in a fireplace, but can be shipped and provided on retail shelves in a relatively compact format.

FIGS. 1 and 2 illustrate a fireplace grate 100 according to an embodiment. In FIG. 1 , the fireplace grate 100 is in an assembled configuration. In FIG. 2 , the fireplace grate 100 is in a packaged and disassembled configuration.

As can be seen in FIG. 1 , the fireplace grate 100 includes a plurality of cross bars 102 that are each attached to two support bars 104. In the example configuration shown in FIG. 1 , the fireplace grate 100 includes four cross bars 102. The number of cross bars 102 may be different in some embodiments, depending on a desired length for the fireplace grate 100. Each cross bar 102 is attached to the support bars 104 with fasteners 106. In the assembled configuration of FIG. 1 , the fireplace grate 100 can support logs and the like while providing sufficient airflow for suitable use in a fireplace.

As can be seen in FIG. 2 , the fireplace grate 100 can be packaged in a disassembled configuration. In the packaged and disassembled configuration, each of the cross bars 102 and the support bars 104 are placed in a nested arrangement that minimizes the overall footprint. In this nested arrangement, the crossbars 102 and support bars 104 are arranged in a box 108. The box 108 in FIG. 2 is shown as transparent in order to illustrate the nested arrangement. The fasteners 106 are also arranged in the box 108. A tool 110 is also provided in the box 110. The tool 110 is provided so that a user can easily assemble the fireplace grate 100 without any additional hardware. The tool 110 is configured to engage each fastener 106. According to an embodiment, the tool 110 is a hex wrench shaped to engage a hex head of each fastener 106.

The nested arrangement of the cross bars 102 and support bars 104 in the box 108 allows the box 108 to have relatively small dimensions. For example, the box 108 holding the entire fireplace grate 100 in the disassembled configuration may have a height more than 50% smaller than a height of the fireplace grate 100 in the assembled configuration. According to an embodiment, the height of the box 108 is less than 33% of the height of the fireplace grate 100 in the assembled configuration.

The height of the box 108 may be selected based on the width of the cross bars 102 and support bars 104 (which may all have the same width) in the nested arrangement.

The length of the box 108 may be selected on the length of the longest component, namely, the length of one support bar 104.

The width of the box 108 may be selected based on the combined thickness of the cross bars 102 and support bars 104 in the nested arrangement, with additional width for the curved ends of the outermost cross bar 102 in the nested arrangement. The assembly hardware, namely the fasteners 106 and tool 110 do not add to the width of the box, because the assembly hardware can be packaged in the box 108 in available space between the curved ends of the outermost cross bar 102.

FIG. 3 illustrates an example assembly procedure. As can be seen, one of the cross bars 102 is positioned over one of the support bars 104 so that corresponding holes in the cross bar 102 and support bar 104 are aligned. The hole in the support bar 104 is threaded. The user inserts the fastener 106 through the hole in the cross bar 102 and rotates the fastener 106 with the tool 110 to engage the threads in the hole in the support bar. In this matter, the cross bar 102 is securely fastened to the support bar 104. The procedure is repeated, with each cross bar 102 spanning between two support bars 104. Each cross bar 102 may be evenly spaced from one another.

As can be seen in FIG. 4 , the hole in the cross bar 102 that receives the fastener 106 may be countersunk to provide a clean appearance to the assembled fireplace grate 100.

FIG. 5 illustrates example alternate embodiments of the fireplace 100. For example, the fireplace grate may be 18 inches long, with four cross bars. As another example, the fireplace grate may be 23 inches long, with five cross bars. As another example, the fireplace grate may be 27 inches long, with five cross bars. Other sizes are contemplated as within the scope of the invention. Other numbers of cross bars and support bars are contemplated as within the scope of the invention.

The table in FIG. 6 demonstrates that the packaged and disassembled configuration of the fireplace grate 100 significantly more compact than the assembled configuration. For example, the height of the assembled configuration of the fireplace grate 100 may be around 4 inches, while the height of the box 108 holding the fireplace grate 100 in the packaged and assembled configuration may be around 1.3 inches. As explained above, the width of the box 108 need only to accommodate the combined thickness of each of the cross bars 102 and support bars 104, with additional width to accommodate the curved ends of one of the cross bars 102.

The relatively compact size of the box 108 and the packaged and assembled configuration of the fireplace grate 100 allows a large number of fireplace grates 100 to be stacked significantly more efficiently compared to a traditional fireplace grate. Thus, storage volume is significantly reduced, which reduces shipping costs because, for example, more fireplace grates 100 can be shipped in a single shipping container. Likewise, a retailer can provide a larger inventory supply on a given retail shelf space. Furthermore, the user can more conveniently handle the fireplace grate 100 from the retail shelf to their car and then into their home.

As another advantage, the fireplace grate 100 is easy to assemble by the user in just a few minutes, and no additional hardware is required.

As another advantage, the box 108 provides sufficient surface area for product information and marketing materials, such as a brand name and/or artwork that the retailer may want to include. For example, the retailer may want the box 108 to include a brand name to improve brand awareness. As another example, the retailer may want the box to include artwork to inform potential users of the utility of the fireplace 100 or to increase the attractiveness of the box 108 to attract more customer interest.

FIGS. 7 and 8 illustrate a fireplace grate 200 according to an alternative embodiment. The fireplace grate 200 is similar to fireplace grate 100 and includes multiple cross bars 202, support bars 204, fasteners 206, box 208 for holding the fireplace grate 200 in a packaged and disassembled configuration with the cross bars 202 and support bars in a nested arrangement, and an included tool 210. While the fireplace grate 100 is illustrated with four cross bars 102, the fireplace grate 200 is illustrated with five cross bars 202. As noted, other numbers of cross bars 102/202 are contemplated. 

What is claimed is:
 1. A fireplace grate comprising: a plurality of cross bars, a plurality of support bars, and a plurality of fasteners, wherein: the plurality of support bars and the plurality of cross bars can be nested together in a disassembled configuration, each fastener is configured to extend through a hole in one of the cross bars and engage a corresponding threaded hole in one of the support bars so that each cross bar can be fastened to the plurality of support bars in an assembled configuration with each cross bar spanning the plurality of support bars, and a width of the fireplace grate in the disassembled configuration is less than 50% of a width of the fireplace grate in the assembled configuration.
 2. The fireplace grate according to claim 1, wherein a height of the fireplace grate in the disassembled configuration is less than 50% of a height of the fireplace grate in the assembled configuration.
 3. The fireplace grate according to claim 2, wherein the height of the fireplace grate in the disassembled configuration is less than 33% of the height of the fireplace grate in the assembled configuration.
 4. A method of providing a fireplace grate, the method comprising the steps of: arranging, in a box, a plurality of cross bars, a plurality of support bars and a plurality of fasteners, wherein the plurality of support bars and the plurality of cross bars are in a nested arrangement in the box in a disassembled configuration, wherein: each fastener is configured to extend through a hole in one of the cross bars and engage a corresponding threaded hole in one of the support bars so that each cross bar can be fastened to the plurality of support bars in an assembled configuration with each cross bar spanning the plurality of support bars, and a width of the fireplace grate in the disassembled configuration is less than 50% of a width of the fireplace grate in the assembled configuration.
 5. The method according to claim 4, wherein a height of the fireplace grate in the disassembled configuration is less than 50% of a height of the fireplace grate in the assembled configuration.
 6. The method according to claim 5, wherein the height of the fireplace grate in the disassembled configuration is less than 33% of the height of the fireplace grate in the assembled configuration. 